Casting apparatus



G. W. ELSEY CAST ING APPARATUS March 5, 1940.

Filed Aug. 23, 1937 3 Sheets-Sheet 1 M5 3 T5 N m m vi n mW A E QM March5, 1940. ELSEY 2,192,787

CASTING APPARATUS Filed Aug. 23, 1937 I5 Sheets-Sheet 2 A A X 4 3 9 4055 ,1 8/ 4 37 46 3 :5

F-T'E -4/0 i 80 g a 5/ 30 m 4 I HHHH IHHIHHH gu my 91.4,,

March 5, 1940.

G. w. ELSEY CASTING APPARATUS Filed Aug. 23, 1937 3 Sheets-Sheet 5 520rge Wf/seg INVENTOR MM V214 'ATTORNEYS Patented Mar. 5, 1940 PATENTOFFICE CASTING APPARATUS George W. Elsey, La Grange, 111., assignor toGeneral Motors Corporation, Detroit, Mich., a cor-' poration of DelawareApplication August 23,

8 Claims.

This invention relates to casting apparatus, and more particularly to amold for die casting.

An object of this invention is to provide a mold for die casting that isvoid of unnecessary complicated parts and easy to assemble anddisassemble in use. I

Another object of this invention is to provide a mold for simultaneouslydie casting fan blades, two conductor windings and spaced end rings forsquirrel cage induction motor rotors without ma chining. I

Another object of this invention is to provide a mold for die castingthat is provided with means for venting the mold, which means does notpermit the escape or waste of an appreciable amount of metal.

Another object of this invention is to provide a mold for die castingthe fan blades, conductors and space end rings for squirrel cageinduction go -motor rotors, which serves in clamping the rotorlaminations in place during the casting operation.

Further objects and advantages of the present invention will be apparentfrom the following description reference being had to the accompanyingdrawings wherein a preferred embodiment of the present invention isclearly shown.

In the drawings: Fig. 1 is a perspective view of a completed rotor. Fig.2 is a vertical sectional view showing a rotor formed by the moldembodying the present invention.

Fig. 3 is a plan View of one of the rotor laminations.

Fig. 5 is a sectional view taken substantially on the line 5--5 of Fig.4.

Fig. 6 is a plan view of a plate member used in the mold.

Fig. 7 is a fragmentary end view of the plate end member looking in thedirection of arrows 'l--'I of Fig. 6.

Fig. 8 is a plan View of a lower ring spacing member.

Fig. 9 is a view taken on the line 9-9 of Fig. 8.

Fig. 10 is a plan view of a lower end ring forming member.

Fig. 11 is a sectional view taken on line I l-H of Fig. 10.

Fig. 12 is a plan view of an upper ring spacing member.

Fig. 13 is a sectional view taken on line 13-43 of Fig. 12.

Fig. 14 is a fragment of an upper end ring form- 5 log member.

Fig. 4 is a view taken on the line 4-4 of Fig. 2.

1937, Serial No. 160,437

Fig. 15 isa sectional view taken on line i5i5 of Fig. 14.

Figs. 16 and l? are plan and side views respec-- tively of a fan bladeforming member.

Referring to Figs. 1 and 3 the magnetic core ill of an inductor motorcomprises a plurality of laminations 2i having relative deep conductorreceiving openings 22 and shallow conductor receiving openings 23. Inorder to cast squirrel cage windings into the conductor receivingopenings the core ill is positioned in a suitable mold formed in such amanner that the openings will be entirely filled with conductor portionsunited by spaced end rings 24 and 25. with fan blades 26 formed integralwith the end rings 24.

In the casting operation, a mold is provided 1 which comprises a basemember 36 formed with a cylindrical wall 3i and an opening includingconical walls 32 and 33, the walls 3| and being separated by an annularledge or shoulder 34. An upper mold member 35 is provided and ispreferably of cup-shaped formation. The upper mold member is formed witha cylindrical wall I 36 and a tapered wall 31 which are separated by anannular ledge or shoulder 38 The closed end of the member 35 is providedwith an annular channel 39 and a plurality of spaced openings 40communicating with the channel 39 to provide outlets for air or gas thatflows through the mold during the casting operation.

The tapered portions 32 and 37 of the members 30 and 35, respectively,receive lower and upper fan blade forming members or inserts 4i and 42respectively. Each of the inserts has a tapered portion 43 complementaryto the tapered portions 32 and '3'! of members 36 and 35 respectively.These inserts are formed with concentric ledges 44 and 45 on diiierentlevels, which form an annular wall It see Fig. 17, and are provided withtapered notches indicated at 46. Each member 4| and 42 is provided Witha tapered boss 47 and a through central opening 48 to receive a shaft49.

The lower end of the shaft 49 carries a plate member 59. This plate isproperly positiohed on the shaft by a projection or pin 5i. The pin iscarried by the shaft and fits into a recess 52 in the plate. The plateis secured to the shaft by a screw 53. The plate is also provided withradial extending notches 54 which correspond with notches 46 in themember 41. The member 4| is adapted to rest upon the plate 50 and it isimportant that the notches 54 of the plate 50 register with the notches46 of the insert 4 i. This is accomplished by providing the member 4|with a projection or pin c5 which extends into a sec ond recess 56 inthe plate 50.

The assembly comprising the shaft 49, plate i i and the member 4! isinserted in the base member 39. When the assembly is positioned in thebase member the tapered portion #33 will fit snugly with the taper 32and the peripheral edge of the ledge 44 will be flush with the shoulder34 to form an annular channel between the cylindrical wall 3I and a wallit. This channel is adapted to re celve a plurality of segmental membersillustrated in Figs. 8 and 9. The members close that portion of thenotches 45 about the wall which communicate with the channel. The1ncmbers 6| are so positioned in the channel th spaces between adjacentsegmental members will not be opposite any of the notches preventingmolten metal from entering the channel during the casting operation.

A pair of semi-circular members 65 rest upon the segmental members iii.These members 65, see Figs. 10 and ii, are provided with a cylindricalportion 66, a. groove iii, a tapered portion which terminates into acylindrical portion 63. The cylindrical portion will fit about thecylindrical wall H3 formed by the ledges M and 45 of the member 4! sothat the upper end of the portion 69 will be flush with the outer edgeor the smaller ledge 45. The partitions "H, formed on the members '55have a plurality of spaced shallow notches '52 which cooperate with thelowermost lamination to provide jet like openings. The tapered portioncooperates with the boss 4! of the member 4! to form an inner annularchannel 13.

A stack of laminations 525, comprising the rotor core, has eachlamination provided with a central opening 15 therethrough that fitsover the shaft 49. A key-way it is also provided in each of thelaminations to fit over a skewed-feather TI. The feather imparts atwistor a circumferential displacement to the stack of laminations 2 I. The

stack of laminations rest upon the ledge providedv between thecylindrical portion iii? and over the groove 67 of the member 85, sothat the openings 22 and 225 will communicate with the channels 13 and6'! respectively; The length of the rotor core is regulated by sizingposts 80 carried by the base member 38.

The upper member 35 of the mold is adapted to receive the insert i2which is similar in construction to the insert M, with the exceptionthat the member 42 is provided with shallow notches 8|. These notchesextend from the notches 45 inwardly so that they communicate with theannular groove 39 to allow air or gas that flows 7 from the mold throughthe channel 39 and thence through the openings til. The upper insert 42is removably secured within the member 35 by studs or projectionscarried thereby and which extend through suitable openings provided inthe closed end of the member 35?. The studs are provided with grooves toreceive U-washers which operate to firmly hold the member 42 against theclosed end of the member as clearly illustrated in Fig. 5. Whentheinsert is secured to the member 35 the lower ledge 4 1 of the insert 42will be flush with the shoulder 38 providing an annular groove betweenthe wall Ill of the insert 42 and the cylindrical wall 36 of member 35.This groove is adapted to receive a second set of segmental members BIand a set of semi-ring members 82, shown in Figs, 14 and 15. The members82 are provided with a ridge 83 tapered on both sides and are assembledadjacent the segmental members SI. The ridge is adapted to rest firmlyupon the uppermost lamination of the rotor core and provide a channelbetween the boss 41 and the ridge connecting with the inner conductorreceiving opening 22. A second set of semi-circular members 84 is alsoadapted to rest on the upper lamination. These members 84 are providedwith shallow radial notches 35 and vertical notches 8t. Thesenotchesprovide outlets for air and gas that flows through the mold as clearlyshown in Fig. 2. The members 84 and the ridge 83 cooperate to form anannular channel coinciding with the outer conductor receiving open lugs23.

When the elements 42, BI, 82 and 84 are assembled in their properrelation to each other, in the upper member 35, the assembly comprisingsaid elements is fitted over the upper end of the shaft 49 the smoothsurfaces of the members 84 and the ridges 83 will engage the uppermostlamination of the rotor core to form spaced inner and outer end ringchannels. The upper member 35 is then secured to the shaft 49, by aC-washer 92 which fits into the groove 93 provided in the shaft toprovide the mold proper.

With the mold properly assembled, the base member 3% of the mold isplaced into an opening 5% of a support Iill and rests upon a ledgeportion Hi2 that is integral with the support. A cylindrical wall Hi3formed integral with the support provides a cylinder I04 for theaccommodation of molten metal and has a piston I06 slidably supportedtherein. The piston is adapted to force molten metal from the cylinderI04 through the openings 54 of the plate and the slots 46 of the memberAll upon movement of the piston in an upward direction. The piston has ashaft l 87 secured thereto and extends through an opening H38 in a wallI09 of the cylinder chamber. The shaft is adapted to transmit theactuating pressure to the piston.

A U-shaped frame member II ll is secured to the support IUI by bolts III and extends over the mold. A threaded aperture H2 in the yoke of theframe member III! has a screw II3 threaded therein. A hand wheel II 4secured to the end of the screw is provided for manually forcing aclamping member H5 against the member 35 to hold the member 35 firmlyagainst the post and hold the assembled parts of the mold in place.

In operation, a quantity of molten metal is placed in the cylinder I04over an asbestos disc I I35 indicated by dot and dash lines above thepiston H36. Then upon fast upward movement of the piston H15 in thecylinder I04, as viewed in Fig. 2 the molten metal is forced through thenotches 54 of plate 59, notches 46 of insert II into the channel upthrough the conductor receiving openings 22 and the correspondingnotches 45 in the upper insert 42. At. the same time molten metal isalso forced through the jet like openings 12 into the channel 61, and upthrough the small conductor openings 23 to the upper outer channel. Asthe molten metal is forced through the mold the air passes out from themold in two paths from the chamber 35. One of the paths for the escapeof gas or air is through the shallow grooves 8|, annular channel 39 andopenings 40. The other path for the escape of air is from the outer ringchannel through the notches 85 and 86 rovided by the ring members 84.

After the metal that has been forced into the mold has cooledsufiiciently to become set, the disc I05 will adhere to the excessmetal.

The

mold may be disassembled, by the steps of loosening the screw 1 I 3,removing the clamping member H5 after which the mold is removed from theopening I00. Then the C-washer is removed from the groove 93. By the useof a hammer or other suitable means, the shaft 49 is forced from themold which causes the plate 50 to sever the excess material and the discI05, indicated by the letter A, along the dotted lines B which is theend of each lower fan blade formed by the notches 46. The advantage ofthe narrow opening is apparent at this time since the excess metal whichsolidifies below the plate 50 is easily broken, away from the fan bladeswhen the shaft 49 is forced from the mold. After the shaft 49 and plate50 are removed from the mold, the upper member 35 is lifted from therotor and the rotor from the base member 30. The arcuate members BI andthe semi-ring members 84 are removed from the fan blades to permit themembers 65 and 82 to be lifted from the end rings formed by thesemembers. Since the base member 30 is removable from the support llll,the complete mold may be removed for disassembly after loosening thescrew H3. This permits the placing of another assembled mold over thecylinder I04 to be filled while the filled mold is being disassembled.Another advantage of the segmental members is apparent at this timesince the members can be easily removed.

While the embodiment of the present invention as herein disclosed,constitutes a preferred form, it is to be understood that other formsmight be adopted, all coming within the scope of the claims whichfollow.

What is claimed is as follows:

1..A device for casting conductors, end rings and fan blades in a rotorhaving conductor openings therein, comprising in combination; a moldcomprising two parts between which the rotor is secured, said mold partseach having an annular recess to which one end of the rotor is exposed,said mold parts also having spaced radial fan blade forming slotscommunicating with the recesses; a set of removable segmental memberssupported in the annular recess of each mold part, each end of the rotorbeing engaged by a set of segmental members, said segmental membershaving flanges for forming two concentric ring channels communicatingwith the conductor openings at each end of the rotor, means providingcross passages through the flanges in one set of segmental members toconnect the ring channels thereof, the construction being such that theconductor openings in the rotor are in direct communication with all thefan blade forming slots and the concentric ring channels and crosspassages of the segmental members provided by the two mold parts.

2. A device for casting conductors, end rings and fan blades in a rotorhaving conductor openings therein, comprising in combination; a moldcomprising two parts between which the rotor is secured, said mold partseach having an annular recess into which an end of the rotor projects,said mold parts having longitudinal spaced radial fan blade formingslots communicating with the recesses and a set of removable segmentalmembers supported in the recess of each mold part, each end of the rotorbeing engaged by a set of segmental members, said segmental membershaving projections for forming concentric ring channels communicatingwith the conductor openings at each end of the rotor, one of thechannels being spaced radially from the fan blade rotor is separatedfrom forming slots, means providing radial notches in the projections inone set of segmental members to connect the ring channels thereof allring channels and fan blade slots being interconnected; and meansconnected with one of the ring channels for introducing molten metal.

3. A device for casting conductors, end rings and fan blades in a rotorhaving conductor openings therein, comprising in combination; a moldcomprising two parts between which the rotor is secured, said mold partsincluding supporting members, each of which is provided with an internalannular shoulder, and a removable insert carried by each mold parthaving a plurality of annular ledges on different, levels, said insertsalso having spaced longitudinal radial slots extending through at leastone of the ledges, one of the ledges of each insert providing shelfportions coextensive with the shoulders of the mold parts to provideannular recesses facing the end of the rotor; a I set of preformedsegmental members supported in the recesses, each end of the rotor beingengaged by a set of segmental members, each set of said segmentalmembers being grooved and cooperating to provide two concentric ringchannels both ring channels communicating with the conductor openings ateach end of the rotor, and the inner ring channel communicating withwhich is provided with an internal annular shoulder, and an insertcarried by each mold part having a plurality of concentric ledges andarranged on different levels, said insert having a plurality of fanblade forming slots, the outermost ledge of each insert providing shelfportions coextensive with the shoulders of the mold parts to provideannular grooves between the supporting members and the inserts whichgrooves normally face the ends of the rotor; and a set of preformedsegmental members supported in each of the grooves of each mold part,each end of the rotor being engaged by a set of segmental members saidsegmental members having fianges forming a pair of concentric ringchannels communicating with the conductor openings at each end of therotor, one of the ring channels at each end of the rotor communicatingwith the fan blade forming slots, while the other ring channel at oneend of the the said slots, means providing cross passages in one set ofsegmental members to connect the concentric ring channels therein; andmeans connecting all ring channels and slots with a single pouringmeans.

5. A device for casting conductors, end rings and fan blades in a rotorhaving conductor openings therein, comprising in combination; a moldcomprising two parts between which the rotor is clamped, said mold partseach having an annular recess to which one end of the rotor is exposed,said mold parts also having spaced longitudinal fan blade forming slots;and removable segmental members supported within the annular recesses,said segmental members having flanges to provide concentric ringchannels at each end of the rotor with the inner channels havingcommunication with the fan blade forming slots and the conductoropenings, means providing radial notches in one set of segmental membersto connect the ring channels whereby all slots and channels areinterconnected and means for clamping mold parts against the rotor influid tight relation whereby casting metal introduced into the moldparts will flow into the fan blade forming slots, concentric ringchannelsand conductor opening to form an integral casting therein.

6. A device for casting conductors, end rings and fan blades in a rotorhaving conductor openings therein, comprising in combination; a moldcomprising two parts between which the rotor is secured, said mold partseach having a recess to which one end of the rotor is exposed, said moldparts also having spaced radial extending fan blade forming slots; a setof removable sections provided with flanges supported within therecesses, said sections when assembled in the recesses cooperating toform concentric ring channels at each end of the rotor with the innerchannels having communication with the fan blade forming slots and therotor conductor openings, means providing radial notches in one set ofremovable sections to inter-connect the ring channels thereof, saidblade ring channels and conductor openings being in communication suchthat molten metal will form an integral casting therein.

' '7. A device for casting conductors, spaced end rings and fan bladesin a rotor having conductor openings therein, comprising in combination;a mold comprising two mold parts between which a rotor is secured, eachmold part having an annular recess facing one end of the rotor, therebeing spaced longitudinal radial fan blade forming slots communicatingwith each recess; and a set of preformed segmental members substantiallyfilling the recess of each mold part, each end of the rotor beingengaged by a set of segmental members, each set of said segmentalmembers providing an inner and an outer ring channel communicating withthe conductor openings at each end of the rotor the inner channels ateach end of the rotor being directly connected with the slots and theconductor openings; and means providing passages in one of segmentalmembers cross connecting the innei and outer ring channels thereof topermit molten metal introduced into the mold to flow into all of thering channels, conductor openings and slots to form an integrallyconnected casting filling the same upon a single pouring operation.

8. A mold for making spaced end rings on a rotor having conductoropenings therein, comprising; an upper mold part and a lower mold partbetween which a rotor is supported, each mold part having an annularrecess; a set of segmental members assembled into the recess of theupper mold part the disposition of said segmental members in the recessbeing such that the members will form concentric ring channels incommunication with the conductor openings at the uppermost end of therotor; a second set of grooved segmental members assembled into therecess of the lower mold part forming concentric ring channels incommunication with the conductor openings at the lowermost end of therotor; means providing cross passages in the second mentioned groovedmembers to connect the ring channels formed therein, the ring channelsprovided by the upper and lower mold parts being in direct communicationby the conductor openings of the rotor supported between the mold partssuch that introduction of molten metal will form spaced end rings on therotor integrally connected by conductor bars in the rotor openings.

GEORGE W. ELSEY.

